Metal construction member

ABSTRACT

A metal construction member is disclosed in which the main body is fabricated from a high yield steel sheet which has a thickness dimension of about 0.015 inches to about 0.045 inches, and a yield strength of about 57 ksi to about 65 ksi, and has a cross sectional shape which imparts increased strength to the metal construction member.

TECHNICAL FIELD

The present invention relates to a metal construction member, and more specifically, to a metal construction member fabricated from a high yield strength steel with a reduced thickness dimension.

BACKGROUND OF THE INVENTION

The use of metal construction members, such as studs, trusses, braces, and the like, has become increasingly popular and necessary in commercial, industrial, and even residential structures. Metal studs are dimensionally stable, lightweight and quite strong, and building codes will often require the use of metal framing members for both interior and exterior walls. These metal studs are joined together by screws or other fasteners to provide walls upon which wallboard is then attached by screws. They may further have apertures formed therein and which allow electrical and plumbing conduits to pass therethrough.

The specific material used to fabricate construction members, and the shape, thickness and yield strengths of these materials, has never been optimized with respect to price and performance. The art is replete with examples of steel construction members which have been designed for specific applications. For example, U.S. Pat. No. 5,687,538 to Frobosilo et al. teaches a metal C-shaped floor joist member with formed, structure-enhancing areas along the web of the member in order to add strength and rigidity not offered in a traditional construction member design. This prior art construction member, however, is overly complex, and expensive to manufacture, and would be difficult to utilize in place of a standard-sized wall stud. In U.S. Pat. No. 6,688,066 to Cottier et al., the thicknesses of the disclosed metal studs is reduced in a wall construction system, but the invention requires these studs to be used with a certain solid material between or adjacent to the studs for adequate strength, and the invention requires specific fasteners such as power driven nails, to join the studs to the solid material. Furthermore, the use of high strength steel for the fabricating of metal studs has not been favored by manufacturers because of the higher costs associated with the material, and the associated difficulties of fastening wall board and the like to this material by employing self tapping screws which are applied by powered screw fastening tools. There is no prior art that teaches the design of a metal construction member in which the specific material, its shape, and its dimensions are optimized to provide substantial cost and weight savings in common, everyday applications where standard metal construction members are currently employed.

A metal construction member fabricated from a high yield strength steel which avoids the shortcomings attendant with the prior art devices and practices utilized heretofore is the subject matter of the present application.

SUMMARY OF THE INVENTION

A first aspect of the present invention relates to a metal construction member which has a main body fabricated from a high yield strength steel sheet which has a reduced thickness dimension, and a cross sectional shape which imparts increased strength to the metal construction member.

Another aspect of the present invention relates to a metal construction member which has a main body having a substantially C-shaped cross section and which is defined, at least in part, by a longitudinally elongated and corrugated web portion, and wherein the main body is fabricated from a high yield strength steel sheet which as a thickness dimension of less than about 0.045 inches, and wherein the corrugated web portion of the main body further defines a pair of longitudinally disposed channels and which impart strength to the main body.

Yet another aspect of the present invention relates to a metal construction member for non load bearing construction applications which has a C-shaped main body which is defined by a web portion which has opposite, longitudinally extending peripheral edges; a pair of flange members which are made integral with the web portion and which individually extend substantially normally upwardly relative to the opposite, longitudinally extending peripheral edges of the web portion; and a pair of return members which are individually made integral with the respective flange portions and which are oriented in substantially parallel spaced relation relative to the web portion. The main body is fabricated from a high yield steel sheet which has a thickness dimension of about 0.015 inches to about 0.045 inches, and a yield strength of about 57 ksi to about 65 ksi, and wherein as the yield strength of the high yield strength steel sheet increases the thickness dimension of the high yield steel sheet decreases.

These and other aspects of the present invention will be described in greater detail hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention are described below with reference to the following accompanying drawings.

FIG. 1 is a perspective view of one form of the construction member which is the subject of the present invention.

FIG. 2 is a cross-sectional, transverse view of the construction member which is seen in FIG. 1.

FIG. 3 is a cross-sectional, transverse view of another form of the construction member which is the subject of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

This disclosure of the invention is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws “to promote the progress of science and useful arts” (Article 1, Section 8).

Referring now to FIGS. 1-3, a construction member which is the subject of the present invention is generally indicated by the numeral 10. The construction member as shown depicts two possible forms of a “C-profile” or “C-shaped” wall stud, although one skilled in the art will recognize that the teachings of the present invention may also be applied to the fabrication of other metal construction members such as trusses, braces, and the like. The construction member 10 may be a wall stud, a floor or ceiling truss or brace, or any other construction member used in a commercial, industrial, or residential construction. Further, the construction member 10 may be used as either a load bearing or a non-load bearing member. In FIGS. 1-3, the construction member 10 is generally shown with a conventional C-shaped cross-section, although it will be recognized that the teachings of the present invention may also be applied to the fabrication of other construction members, which may have, for example, a U-shape or an H-shape. The purpose of these assorted cross-sectional shapes is to, on the one hand, impart increased strength to the metal construction member 10, or to provide surfaces upon which another construction member, or wall board, for example, may be attached.

Referring still to FIGS. 1-3, the construction member 10 comprises a main body 11 which has a first end 12 and a second end 13. The length of the construction member is defined as the distance between the first and second ends 12 and 13, and is generally indicated by the numeral 16. It should be recognized that the length dimension 16 of the construction member 10 can vary greatly depending upon the structural application of same. The main body 11 of the construction member 10 is also defined by a first side 14 and a second side 15. A web portion 40 extends between the first side 14 and the second side 15, and is discussed in greater detail below. In the substantially C-shaped cross-sectional shape shown in FIGS. 1-3, the first side 14 comprises a first flange member 20 which extends perpendicularly, upwardly, relative to the web 40. Similarly, the second side 15 comprises a second flange member 21 which also extends perpendicularly, upwardly, relative to the web 40. The first and second flange members 20 and 21 are disposed in predetermined substantially parallel, spaced relation, one relative to the other. The first and second flange members 20 and 21 also have a width dimension 22 and 23, respectively, which also defines the width dimension of the construction member 10. Typically, the width dimension 22 and 23 of flange members 20 and 21, respectively, is 1 and ⅞ inches for a standard wall stud. Of course, one skilled in the art will recognize that the respective width dimensions of the respective flange members 20 and 21 may vary depending upon the particular cross-sectional shape of the construction member and the structural application in which it is used.

Referring still to FIGS. 1-3, the main body 11 of the construction member 10 also comprises a first return member 30, which is made integral with the first flange member 20, and a second return member 31, which is made integral with the second flange member 21. Each return member 30 and 31 are oriented in substantially perpendicular relation relative to the respective flange members 20 and 21, and are further disposed in substantially parallel, spaced relation relative to the web portion 40. The intersecting corners 34 and 35 between the first and second return members 30 and 31, and the first and second flange members 20 and 21, respectively, are typically rounded or knurled so as to provide increased structural strength. The return members 30 and 31 each have a width dimension 32 and 33, respectively, which is typically less than about 7/16 inches and may range from about ⅜ inches to about 7/16 inches. Of course, one skilled in the art will recognize that this width dimension may vary considerably depending upon the particular cross-sectional shape of the construction member chosen, and the structural application in which it is used.

The main body 11 of the construction member 10 also comprises a web portion 40. As shown in FIGS. 1-3, the web portion 40 extends from the first flange member 20 to the second flange member 21, and is further made integral with each of the first and second flange members 20 and 21. The intersecting corners 42 and 43 between the web portion 40, and the first and second flange members 20 and 21, respectively, are typically rounded or knurled so as to provide increased structural strength. The web portion 40 has a width dimension 41, which may range from about 1 and ⅝ inches to about 12 inches, depending upon the structural application in which the construction member 10 is used.

As seen in FIG. 3, the web portion 40 in one possible form of the invention may be characterized as substantially planar or otherwise featureless. In another possible form of the invention, such as seen in FIGS. 1 and 2, the web portion 40 may be corrugated, at least in part, or may include other features such as indentations, deformations or the like, and which are made in the web portion 40, and which provide increased strength, and rigidity for the main body 11 of the construction member 10. In the form of the invention as shown in FIGS. 1 and 2, the corrugated web portion 40 is defined, at least in part, by one or more longitudinally oriented channels 44, which are formed therein during the fabrication of the construction member 10. The longitudinally oriented channels 44 have a width dimension 45 which may lie in a range of between about 0.05 inches to about 4 inches, although the width dimension 45 of each channel 44 may differ depending upon the application. Further, the longitudinally oriented channels 44 also have a depth dimension 49, which may lie in a range of between about 0.05 inches to about 0.5 inches. Similarly, the depth dimension could conceivably vary depending upon the application. In the form of the invention as shown in FIGS. 1 and 2, the web portion 40 of the main body 11 has opposite longitudinally oriented and substantially parallel peripheral edges 48 which are located adjacent to the respective longitudinally oriented channels 44. The peripheral edges 48 adjacent to the channels 44 define an intermediate region 46 of the web portion 40, and which is located between the peripheral edges 48. This intermediate region has a width dimension 47 of about 0.5 inches to about 11 inches, depending upon the width dimension 41 of the web portion 40. It will be recognized that a corrugated web portion 40 may have more than two corrugations, and thus a construction member 10 may have multiple longitudinal channels 44; peripheral edges 48; and several intermediate regions 46. The number, cross-sectional shape, and width dimensions of the corrugations may vary substantially in various forms of the invention in order to provide adequate structural strength and rigidity of the construction member 10. These features will vary based upon the width dimension 41 of the member 10; the gauge of material used to fabricate the construction member; and yield strength of the material employed in the fabrication of the construction member 10.

Referring still to FIGS. 1-3, a salient feature of the present invention is to provide a construction member 10 having a main body 11 which is fabricated from a high yield strength steel sheet, and which has a reduced thickness dimension in relative comparison to the steel sheets which are presently used in the fabrication of prior art construction members. Currently, the thickness dimension of the steel sheets used to fabricate the prior art construction members have a thickness dimension of about 0.0179 inches and greater, and a yield strength of about 33 ksi. “Yield strength” for purpose of this application, is defined in engineering and the material sciences as the stress at which a material begins to plastically (i.e., inelastically, or non-reversibly) deform. It is commonly measured in kilopounds per square inch (ksi) or megapascals (MPa). In the present invention, as the yield strength of the high strength steel sheet increases, the thickness dimension of the high strength steel sheet decreases. In one form of the invention, the high strength steel sheet has a yield strength of greater than about 57 ksi, and in another form of the invention, the yield strength lies in a range of greater than about 57 ksi to less than about 65 ksi. This allows the use of a steel sheet with a thickness dimension that lies in a range of about 0.015 inches to about 0.045 inches. Thus, if a high strength steel sheet with a yield strength of about 65 ksi is employed, the steel sheet may have a thickness of about 0.015 to about 0.030 inches. Further, where a high strength steel sheet with a yield strength of about 57 ksi is used, the steel sheet may have a thickness of about 0.030 to about 0.045 inches. The use of high strength steel sheets with these reduced thickness dimensions for the main body 11 of the construction member 10 has not been utilized heretofore with conventional stud wall applications, especially for non-load bearing walls. Moreover, the teachings of the prior art suggest that such reduced thickness sheet steel construction or framing members should only be used with a layer of solid sheet material in order to provide the requisite strength and rigidity. Thus, the prior art teaches away from the application of high strength steel sheet with reduced thicknesses in conventional stud wall applications, including those in non-load bearing walls, as is possible with the present invention.

The American Society for Testing and Materials (ASTM) published a Standard Specification for Nonstructural Steel Framing Members as Designation: C 645-00 (where “00” indicates the year of the Standard's adoption). The C 645-00 Standard specifies a minimum thickness of 0.0179 inches before application of protective coating. Effective properties for various studs under the Standard, as calculated in accordance with the American Iron and Steel Institute (AISI) specifications, are based on a yield strength, Fy=33 ksi. The ASTM Standard does not make an express allowance for the use of high strength steel sheet, such as described above. Instead, a clear inference exists that high strength steel sheet would not meet the ASTM Standard. Based on the accepted ASTM Standard, it is thus surprising to construct a framing member using high strength steel sheet.

Further, and more surprisingly, the reduced thickness dimension of the high strength steel sheets as described above has not impaired, in any significant fashion, the use of traditional self tapping screws for attachment of wall boards or other construction members to construction member 10. Additionally, from an economic standpoint, the high strength reduced thickness steel sheets have not significantly increased the cost of the resulting product even though the raw material is much greater in cost pound for pound when compared with the steel used heretofore to fabricate the prior art construction member. The observations indicated, above, support a conclusion that the specific material used to fabricate construction members, and the shape, thickness and yield strengths of these materials, has never been optimized with respect to price and performance.

Operation

The operation of the described embodiments of the present invention are believed to be readily apparent and are briefly summarized at this point.

In one of its broadest aspects, the invention relates to a metal construction member 10 that comprises a main body 11 fabricated from a high strength steel sheet which has a reduced thickness dimension, (in relative comparison to current industry standards which is now 0.0179 inches or greater) and a cross-sectional shape which imparts increased strength to the metal construction member. The high strength steel sheet has a yield strength of about 57 ksi to about 65 ksi, and a thickness dimension of about 0.015 to about 0.045 inches.

In another aspect of the present invention, a metal construction member 10 has a main body 11 having a substantially C-shaped cross section. The main body 11 is defined, at least in part, by a longitudinally elongated and corrugated web portion 40, and which further defines a pair of longitudinally disposed channels 44, and which impart strength to the main body.

In yet another aspect of the invention, a metal construction member 10, for use in non-load bearing construction applications, has a C-shaped main body 11 which is defined by a web portion 40 which has opposite, longitudinally extending peripheral edges 48, a pair of flange members 20 and 21 which are made integral with the web portion 40, and which individually extend substantially normally upwardly relative to the opposite, longitudinally extending peripheral edges 48 of the web portion 40. Further, the main body 11 defines a pair of return members 30 and 31 which are individually made integral with the respective flange portions 20 and 21, and which are oriented in substantially parallel spaced relation relative to the web portion 40. The main body 11 is fabricated from a high strength steel sheet which has a thickness dimension of about 0.015 inches to about 0.045 inches, and a yield strength of about 57 ksi to about 65 ksi. As the yield strength of the high strength steel sheet increases, the thickness dimension of the high strength steel sheet decreases.

In compliance with the statute, the invention has been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the invention is not limited to the specific features shown and described, since the means herein disclosed comprise preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents. 

1. A metal construction member, comprising: a main body fabricated from a high yield strength steel sheet which has a reduced thickness dimension, and a cross sectional shape which imparts increased strength to the metal construction member.
 2. A metal construction member as claimed in claim 1, and wherein the high yield strength steel sheet has a yield strength of greater than about 57 ksi.
 3. A metal construction member as claimed in claim 2, and wherein the high yield strength steel sheet has a yield strength of less than about 65 ksi.
 4. A metal construction member as claimed in claim 1, and wherein the reduced thickness dimension of the high yield strength steel sheet lies in a range of about 0.015 to about 0.045 inches.
 5. A metal construction member as claimed in claim 1, and wherein the high yield strength steel sheet comprises a steel having a yield strength of greater than about 57 ksi, and a thickness dimension of less than about 0.045 inches.
 6. A metal construction member, as claimed in claim 1, and wherein the main body of the metal construction member has a substantially C-shaped cross section which is defined, at least in part, by a web portion.
 7. A metal construction member as claimed in claim 6, and wherein the web portion of the main body is corrugated, at least in part.
 8. A metal construction member as claimed in claim 7, and wherein the main body of the metal construction member further comprises a pair of flange members which are made integral with the web portion and which extend normal upwardly relative thereto, and which are disposed in predetermined spaced relation, one relative to the other, and wherein the main body of the metal construction member further comprises a pair of return members which are individually made integral with respective flange members and which are oriented in substantially perpendicular relation relative to the individual flange members, and are further disposed in substantially parallel spaced relation relative to the web portion.
 9. A metal construction member as claimed in claim 8, and wherein the web portion of the main body has a width dimension of about 1 and ⅝ inches to about 12 inches; the flange members of the main body have a width dimension of about 1 and 7/16 inches; and the return members of the main body have a width dimension of less than about 7/16 inches.
 10. A metal construction member as claimed in claim 9, and wherein the main body is fabricated from a high yield strength steel sheet having a yield strength of greater than about 57 ksi, and a thickness dimension of less than about 0.045 inches.
 11. A metal construction member as claimed in claim 10, and wherein the corrugated web portion is defined, at least in part by a pair of longitudinally oriented channels which are formed therein, and which have a width dimension which lies in a range of about 0.05 inches to about 4 inches.
 12. A metal construction member as claimed in claim 11, and wherein the corrugated web portion has opposite longitudinally oriented peripheral edges, and wherein the respective longitudinally oriented channels are located adjacent to the respective longitudinally oriented peripheral edges, and wherein the corrugated web portion has an intermediate region located between the longitudinally oriented channels, and which has a width dimension of about 0.5 inches to about 11 inches.
 13. A metal construction member as claimed in claim 12, and wherein the respective longitudinally oriented channels each have a depth dimension of about 0.05 inches to about 0.5 inches.
 14. A metal construction member, comprising: a main body having a substantially C-shaped cross section and which is defined, at least in part, by a longitudinally elongated and corrugated web portion, and wherein the main body is fabricated from a high yield strength steel sheet which as a thickness dimension of less than about 0.045 inches, and wherein the corrugated web portion of the main body further defines a pair of longitudinally disposed channels and which impart strength to the main body.
 15. A metal construction member as claimed in claim 14, and wherein the thickness dimension of the high yield strength steel sheet is greater than about 0.015 inches.
 16. A metal construction member as claimed in claim 14, and wherein the high yield strength steel sheet has a yield strength of about 57 ksi to about 65 ksi.
 17. A metal construction member as claimed in claim 14, and wherein the thickness dimension of the high yield strength lies in a range of about 0.015 inches to about 0.045 inches; and the yield strength of the high yield strength steel sheet lies in a range of about 57 ksi to about 65 ksi, and wherein as the yield strength of the high yield strength steel sheet decreases the thickness dimension of the high yield strength steel sheet increases.
 18. A metal construction member as claimed in claim 14, and wherein the respective longitudinally disposed channels have a width dimension of about 0.05 to about 4 inches, and a depth dimension of about 0.05 to about 0.5 inches.
 19. A metal construction member as claimed in claim 14, and wherein the yield strength of the high yield steel sheet is about 65 ksi when the thickness dimension of the high yield strength steel sheet is about 0.015 to about 0.030 inches, and wherein the yield strength of the high yield strength steel sheet is 57 ksi when the thickness dimension of the high yield strength steel sheet is about 0.030 to about 0.045 inches.
 20. A metal construction member for non load bearing construction applications, comprising: a C-shaped main body which is defined by a web portion which has opposite, longitudinally extending peripheral edges, a pair of flange members which are made integral with the web portion and which individually extend substantially normally upwardly relative to the opposite, longitudinally extending peripheral edges of the web portion, and a pair of return members which are individually made integral with the respective flange portions and which are oriented in substantially parallel spaced relation relative to the web portion, and wherein the main body is fabricated from a high yield steel sheet which has a thickness dimension of about 0.015 inches to about 0.045 inches, and a yield strength of about 57 ksi to about 65 ksi, and wherein as the yield strength of the high yield strength steel sheet increases the thickness dimension of the high yield steel sheet decreases.
 21. A metal construction member as claimed in claim 20, and wherein web portion has a length dimension of about 1 and ⅝ inches to about 12 inches.
 22. A metal construction member as claimed in claim 21, and wherein the respective flanges have a width dimension of at least about 1 and 7/16 inches.
 23. A metal construction member as claimed in claim 22, and wherein the respective return members have a width dimension of about ⅜ inches to about 7/16 inches.
 24. A metal construction member as claimed in claim 23, and wherein the web portion of the main body is corrugated.
 25. A metal construction member as claimed in claim 24, and wherein the corrugated web portion has at least one longitudinally disposed channel formed therein which has a width dimension of about 0.05 inches to about 4 inches; and a depth dimension of about 0.05 inches to about 0.5 inches. 